KR20050023416A - Patterned polymer articles - Google Patents

Abstract

Products 100, such as elongate strips 101, 101 ′ for use as masking materials in vehicle spray coating, are formed from cold weldable compressible polymer materials and modified under pressure to retain the desired shape upon pressure relief. The surface pattern is provided to the cold welded region 102. The surface pattern may be decorative to reinforce the aesthetics of the appearance of the product 100. Alternatively, the surface pattern may be functional to give the product the desired characteristics and / or to inform the user. The information may be in the form of letters, numbers, symbols, pictures, or any combination thereof that identifies the product, its source, or provides a method of use. The surface pattern may be formed during the cold welding operation forming process or may be applied separately after the cold welding operation operation.

Description

Patterned Polymer Products {PATTERNED POLYMER ARTICLES}

The present invention relates to a polymer product or an improvement thereof. More specifically, the present invention relates to a polymer foamed article and a method for producing a polymeric foam article in which the surface pattern is applied to the area of the article. The invention has particular use as a foamed product for use as a masking material in vehicle painting, although not limited thereto.

Applicant's co-pending British Patent Application No. 021637.1, filed July 13, 2002, having a flexible web portion extending along the length of the strip and having a width transverse to the length of the strip. A polymer foam article is disclosed for use as a masking material comprising an elongate strip of material, wherein the region of foam material is deformed under pressure so that when pressure is removed, a strained region is created in the web portion. The web portion is formed by the forming process.

Applicant further discloses applying a surface pattern to the flexible web portion during the molding process to provide the web portion with any desired properties of stress relief, stiffness, strength or flexibility in a particular plane or direction.

The present invention develops and extends the use for masking materials generally disclosed for the uses detailed in the applicant's application above for foamed products.

At least some embodiments provide surface patterns as well as methods of surface pattern formation for both functional and decorative ranges of use.

1 shows a schematic cross section of a foamed article for use as a masking material disclosed in Applicant's co-pending UK patent application no. 0216373.1.

FIG. 2 shows a method and apparatus for producing the foamed article shown in FIG. 1.

FIG. 3 illustrates an adhesive delivery system for use with the method and apparatus shown in FIG. 2.

4 illustrates the use of the foamed article shown in FIG. 1 as a masking material for masking the gap between two parts of a vehicle.

5-14 show another patterned contact surface for applying a surface pattern to the connecting web of the foamed article shown in FIG. 1 using the method and apparatus of FIG. 2, wherein FIGS. 8-14 are FIGS. The scale is extended compared to the contact surface of FIG.

Figure 15 is a schematic perspective view of another foamed article for use as the masking material of the present invention.

Figure 16 is a partial view on line 16-16 of Figure 15;

FIG. 17 is a partial view on line 17-17 of FIG.

Figure 18 is a schematic perspective view of another foamed article for use as the masking material of the present invention.

Figure 19 is an end view of the foamed article shown in Figure 18;

Figure 20 is an end view of the foamed article shown in Figure 18 with the cord and tab separated.

Figure 21 is a schematic perspective view of another foamed article for use as a masking material according to the present invention.

FIG. 22 is a partial view on line 22-22 in FIG. 21;

FIG. 23 is a partial view on line 23-23 in FIG.

Figure 24 is a schematic perspective view of another foamed article for use as a packing material according to the present invention.

Fig. 25 is a partial view on line 25-25.

Figure 26 is a partial view on lines 26-26.

Figure 27 is a schematic perspective view of a foamed article for use as an adhesive backing tape according to the present invention.

<Detailed Description>

1-3 show a foamed product 10 as disclosed in Applicant's co-pending British Patent Application No. 0216373.1 and an apparatus for manufacturing the foamed product 10. The product 10 is for use as a masking material between two parts of the vehicle in spray painting, as shown in FIG.

As shown in FIG. 1, the foamed product 10 comprises an elongated foam strip 11 having two lobes 12, 13 of elliptical cross section connected by an integral web 14. Each lobe 12, 13 has a major axis transverse to the length of the foam strip 11, and the connecting web 14 is aligned with the major axis of each lobe 12, 13.

In this embodiment, the lobes 12, 13 are of different cross-section and the thickness of the web 14 in the transverse direction relative to the length of the foam strip 11 is equal to the amount of the transverse direction relative to the length of the foam strip 11. Smaller than the thickness of the lobes 12, 13. However, it will be appreciated that the lobes 12, 13 and connecting web 14 need not be of any other type as disclosed in the applicant's co-pending UK patent application described above.

Suitable dimensions of the foam strip 10 for masking various sizes and shapes commonly found between automobiles, in particular passenger cars, for example front doors or rear doors or hoods or between trunks or tailgates and adjacent bodies Is given in 1

A (thickness) B (width) C (width) C '(thickness) D (width) E (thickness) 4.5 mm 4.5 mm 3.5 mm 1 mm 13.5 mm 12 mm

It will be appreciated that these dimensions are given by way of example and not by way of limitation, and may be changed to any dimension depending on the particular requirements for any given use of the foam strip 11.

The foam strip 11 may be made of any suitable polymeric foam material. Preferred foam materials are polyester or polyurethane or polyolefin but it will be appreciated that other foam materials familiar to those skilled in the art may be used.

In this embodiment, the foam strip 11 is a polyester or polyurethane foam. Although it is understood that other foam materials may be used, a suitable foam is the trade name “X4200AM”, commercially available from Caligen Foam Limited.

The foam strip 11 is provided with a longitudinally extending adhesive strip 15 on which the foam strip 11 can be detachably fixed in place on one side of the web 14. In other embodiments (not shown), the adhesive strip may extend over some or all of the lobes 13. The adhesive strip 15 may be, for example, a pressure sensitive adhesive such as a hot melt rubber adhesive applied by any suitable means such as die coating.

In this embodiment, the adhesive strip 15 is applied across the entire width of the web 14, but need not be so and that the adhesive strip 15 may be applied across a portion of the width of the web 14. You will know. Assuming that the foam strip 11 is effectively secured in place so that the lobes 12, 13 move independently without the movement of one lobe causing the movement of another lobe, the adhesive strip 15 is also longitudinally It may be continuous or discontinuous.

The method and apparatus for forming the foamed article 10 of FIG. 1 will now be described with reference to FIGS. 2 and 3 starting from a flat sheet of foam.

As shown in FIG. 2, the foam sheet 16 has a plurality of uniformly spaced and parallel extending in the longitudinal direction of the foam sheet 16 by application of pressure through a plurality of laterally spaced blades 17. Seam 18 is provided. The blade 17 has an approximately 0.5 mm wide blunt end that compresses the foam so that the top and bottom surfaces melt together along the seam 18 to prevent the foam from returning to its original form upon pressure relief. Have

The foam sheet 16 is also compressed between the seams 18 to form the web 14 by the application of pressure through the plurality of blades 19. One blade 19 is provided between each pair of blades 17 and offset towards one of the blades 17. The ends of the blades 19 are wider than the blades 17 and partially cover the area of the foam sheet 16 between the seams 18 to prevent the foam material from returning to its original form upon pressure release. Only compresses.

In this way, the desired shape of the foamed product 10 is produced with two elliptical lobes 12, 13 of different cross sections connected by flat webs 14. Foam sheets 16 may be separated along the seam to form individual foam strips 11.

Strip 15 of pressure sensitive adhesive may be applied to web 14 before or after separating foam strip 11 along seam 18 by a suitable adhesive transfer system, as schematically shown in FIG. The system comprises a plurality of separate individual dies 20 positioned over the connecting webs 14 of the foam strip 11. The die 20 is supplied with adhesive from a remote source (not shown) via a separate flow channel 21, and an adhesive strip 15 is applied to the connecting web 14 of the foam strip 11.

The foam strip 11 may be stored and supplied as a roll of a predetermined length wound on a core (not shown) or itself which may be unwound and detached to the desired length by the end user. When one or more foam strips 11 are wound on a common core that are joined or separated together by seams 18 and unwound the foam strips 11 by a desired length, they can be manually separated by the end user.

It will be appreciated that the relative size of the lobes 12, 13 is determined by the offset of the flat blade 18 between the blades 17 and may vary to provide any desired shape of the foamed product 10. The spacing of the lobes 12, 13 can also be changed by varying the width of the flat blade 19.

In this method, the foam sheet 16 is compressed by the blades 17, 19 while the foam sheet 16 is in a stationary state, and the foam sheet 16 provides a new area of the sheet 16 to be molded. By advancing the sheet 16 between the forming operations, it is formed in the required shape in a series of steps. In another method (not shown), the blades 17 and 19 are replaced with rotating disks, and the foam sheet 16 is formed in the required shape in a continuous manner by feeding the sheet 16 past the disk.

Referring to Fig. 4, a foam strip 11 is shown which masks the gap between the post 2 and the door 1 of the vehicle when spray painting the vehicle. The foam strip 11 is fixed to the base surface of the post 2 by the adhesive strip 15 so that the non-adhesive side of the small lobe 12 contacts the side of the post 2 at the Y point.

When the door 1 is closed, the large lobe 13 is folded upward by contact with the base surface of the post 2 so that the non-adhesive side of the lobe 13 contacts the inner surface of the door 1 at the X point. do. In this way, during vehicle spray painting, the gap 3 is closed to prevent the paint from passing through the gap 3.

It will be appreciated that the web 14 causes the lobes 12 and 13 to move independently of each other so that the force applied to the lobe 13 by the door 1 is not transmitted to the lobe 12.

In this way, the adhesive-free contact between the lobes 12 and the sides of the posts 2 is not affected by the compression of the lobes 13 and the adhesive strip 15 is covered to form the hard edges when spraying the vehicle. prevent.

In addition, the foam strips 11 can be configured to close the gaps 3 of different sizes and / or shapes, by hinged the movement of the lobes 13 about the webs 14, which movements are determined by the lobe 12. Does not change the position of).

Thus, when the door 1 is closed, there is no tendency for the lobe 2 to elevate the side of the post 2 to expose the adhesive strip 15.

In this way, smooth edges are formed at the interface between the non-contacting surface of the post 2 and the non-contacting surface that extends in the longitudinal direction where the edge of the lobe 12 contacts the side of the post 2 at the Y point.

Smooth edges are also formed at the interface between the non-sticking surface of the door 1 and the non-sticking surface extending longitudinally in which the edge of the lobe 13 contacts the inner surface of the door 1 at the X point.

It will be appreciated that the gap 3 filling function, which prevents the paint from passing through the gap 3, is performed by combining the lobes 12, 13 with the faces of the door 1 and the post 2.

Moreover, the foam strip 11 has a gap 3 of different size and shape independent of the corner forming function performed by each lobe 12, 13 in contact with the faces of the post 2 and the door 1. It can be configured to fill.

As a result, smooth edges can be formed between the painted and masked areas on both the post 2 and the door 1.

In this embodiment, the lobe 12 provides a non-stick zone extending longitudinally of the strip on one side of the adhesive strip 15 and has a transverse width of 4.5 mm (Table 1).

Applicants have found that the non-adhesive area can be of narrow width without exposing the adhesive strip 15, and in general, a width of 2 mm is the non-adhesive surface of the lobe 12 and the part to which the strip is fixed by the adhesive strip. It has been found that it may be sufficient to maintain contact between them.

The connecting web 14 has a flat surface formed by compressing a foam material having a blade 19 having a smooth contact surface. More preferably, according to the invention, the connecting web 14 has a surface pattern formed by compressing a foam material having a blade with a patterned contact surface. In this way, the surface pattern applied to the connecting web 14 is integrally formed of foam material during the molding process. As a result, the surface pattern cannot be removed or changed without damaging the product so that the user of the product can clearly see.

The surface pattern may be decorative. For example, to reinforce the aesthetics of the product 11, the surface pattern gives the web 14 a visually distinguishable appearance. Alternatively or additionally, the surface pattern may be functional. For example, the surface pattern may alter the physical properties or properties of the connecting web 14 such that the product 11 is suitable for a particular application. Alternatively, the surface pattern may provide a visual indication device of information identifying the product or its source or use thereof. For example, the surface pattern may include an indication applied to the connecting web 14. The indication may be a picture in the form of letters, numbers, symbols or phrases or graphics.

The surface pattern may be inserted (depressed) into the surface of the connecting web 14 by providing a raised (elevated) pattern on the contact surface of the blade 19. Alternatively, the surface pattern may be raised (raised) over the surface of the connecting web 14 by providing a pattern inserted (depressed) in the contact surface of the blade 19.

The contact surface of the blade 19 may be provided with a coloring material which is transferred to the foam of the connecting web 14 such that the surface pattern on the web 14 has a color that contrasts with that of the residue of the web 14. In this way, the visual appearance of the surface pattern is reinforced.

Alternatively or additionally, another surface finish on the contact surface of the blade 19 forming the surface pattern such that the final surface pattern has a different surface finish, for example a texture, to the surface finish of the adjacent surface of the web 14. By providing, the visual appearance of the surface pattern may be reinforced.

5-14 show these examples of contact surfaces of the blades 19 which can be employed to apply decorative and / or functional surface patterns to the connecting webs 14.

5 shows a contact surface 19a with an array of recessed notches 23 forming a plurality of raised and parallel ribs extending in the longitudinal direction of the foam strip 11 which increase the curvature of the web 14 in this direction. A blade 19 is shown having.

6 shows a recessed notch 24 forming a plurality of raised and parallel ribs extending transverse to the longitudinal direction of the foam strip 11 which increases the stiffness of the web 14 against curvature in this direction. A blade 19 having a contact surface 19b having

7 shows a recessed notch forming a plurality of raised and parallel ribs extending at an angle between 0 ° and 90 ° with respect to the longitudinal direction of the foam strip 11 to alter the bending and stiffness characteristics of the connecting web 14. A blade 19 having a contact surface 19c with an array of 25 is shown.

8 shows a contact surface with an array of recessed notches 26 forming a plurality of raised chevrons extending in the longitudinal direction of the foam strip 11 to alter the bending and stiffness characteristics of the connecting web 14. A blade 19 having 19d is shown.

9 shows a contact surface 19e having an array of recessed notches 27 forming a plurality of raised corrugated ribs extending in the longitudinal direction of the foam strip 11 altering the bending and stiffness characteristics of the connecting web 14. A blade 19 is shown having.

FIG. 10 has an array of recessed notches 28 forming a plurality of raised corrugated ribs extending transverse to the longitudinal direction of the foam strip 11 altering the bending and stiffness characteristics of the connecting web 14. A blade 19 having a contact surface 19f is shown.

As can be seen, each of the contact surfaces 19a to 19f has an appearance that alters the physical properties of the web 14 to the connecting web 14, ie having a functional and aesthetically pleasing connection to the connecting web 14. To provide a surface pattern having decorativeness.

The blades 19 may be arranged such that the surface pattern provided by each of the contact surfaces 19a to 19f is substantially continuous in the longitudinal direction of the strip 11. Alternatively, the blade 19 may have contact surfaces 19a to 19f such that the surface pattern is discontinuous in the longitudinal direction with breaks or gaps in the surface pattern provided at regular or irregular intervals in the longitudinal direction. The brake or gap may be provided with other forms of marking as described below.

The surface pattern created by the contact surfaces 19a to 19f is merely illustrative of the present invention, and blades 19 having different shapes and shapes of recessed notches in the contact surface may produce any desired surface pattern on the connecting web 14. It will also be appreciated that it may be employed to provide. For example, FIG. 11 shows a blade 19 with a contact surface 19g having an array of recessed notches 29 forming a decorative surface pattern of raised circular ribs that repeat in the longitudinal direction of the foam strip 11. It is shown.

12-14 show these examples of the contact surfaces of the blades 19 which can be employed to apply the surface pattern to the connecting web 14 in a display form to provide information related to the product to the user. . For example, to identify a product or its source or use.

FIG. 12 shows a recessed notch 30 forming a raised number "3" and a raised letter "M" arranged to apply a marking "3M" to the connecting web 14 to identify the manufacturer of the strip 11. 31 shows a blade 19 having a contact surface 19h provided.

The marking "3M" is repeated at longitudinally spaced intervals of the strip 11, and the surface area of the connecting web 14 between these markings is flat or a surface such as any pattern shown in Figures 5-11. Patterns may be provided. FIG. 13 shows a contact surface combining the recessed notches 30 and 31 shown in FIG. 12 and the recessed notches 24 of FIG. 6 to provide the connecting web with a marking " 3M " A blade 19 having 19i is shown.

It will be appreciated that any combination of letters and / or numbers may be employed to identify a product, such as an article code and / or a source, such as a manufacturer. It will also be appreciated that the marking may consist of letters and / or numbers arranged to provide a method of use of the product.

14 shows a blade 19 having a contact surface 19j provided with a recessed notch 32 forming a symbol or picture on a connecting web 14 which is repeated at longitudinally spaced intervals of the strip 11. Doing. Again, the symbol or figure may be combined with any other form of surface pattern described herein.

Each of the contact surfaces 19a to 19j of the blades 19 shown in Figs. 5 to 14 applies a surface pattern to one side of the compressed region, and the inverse of the surface pattern is simultaneously formed on the opposite side. The surface pattern may be arranged to be applied to both sides of the compressed region and to offset the surface pattern so as not to interfere with the surface pattern thus formed. This may be desirable if the surface pattern includes information in the form of letters and / or numbers. The offset surface pattern applied to both sides of the compressed region may be the same or different.

In other embodiments (not shown), the surface patterns applied to both sides of the compressed region may be arranged so that the patterns cooperate to produce the desired combined pattern on both sides.

15-17, they show a second embodiment of a foamed article 100 according to the present invention.

Foamed product 100 includes two elongated cords 101, 101 ′ in generally circular cross sections joined together by a series of compressed regions 102 in the form of roughly diamonds. Compressed regions 102 are arranged such that adjacent regions 102 in the longitudinal direction contact each other at vertices 102a and 102b. As shown, each compressed region 102 is provided with a marking “3M” to identify the manufacturer of the product 100. It will be appreciated that the compressed region 102 may be provided with any other form of surface marking as described above.

The article 100 is a rotating blade (not shown) having a recess corresponding to an indication to be applied to the article 100 provided in the diamond shaped formation and a peripheral surface formed with a diamond shaped formation bonded at the vertex in the peripheral direction. May be produced by compressing the flat sheet of foam into

In the product 100, the compressed region 102 is divided in half to form a series of individual triangular compressed regions 102, 102 ′ in the longitudinal direction of each of the codes 101, 101 ′. A seam 103 (shown in outline in FIG. 15) may be provided where 101 and 101 ′ may be separated. Alternatively, the cords 101 and 101 'may be separated by scissors.

The cords 101, 101 ′ may be used as masking materials to mask gaps between two parts of a vehicle when spraying a vehicle. The cords 101 and 101 'are held in place by longitudinal adhesive strips (not shown) applied to the respective cords 101 and 101', and the compressed regions 102 and 102 'allow the user to Holds (101, 101 ') to provide tabs for accurately positioning and securing the codes (101, 101').

18-20, a third embodiment of a foamed article 200 according to the present invention is shown.

The foamed product 200 includes a cord 201 having a generally circular cross section for use as a masking material for masking the gap between two parts of a vehicle when spraying a vehicle. The cord 201 is provided with a longitudinal flange 202 formed by compressing the foam material and a longitudinal adhesive strip (not shown) for securing the cord 201 in use. The flange 202 provides a tab to aid user positioning in use and to secure the cord 201 and is connected by a seam 203 so that it can be detached from the cord 201 when the cord 201 is in place. (Figure 20). Alternatively, the flange 202 may be left in place to help mask the gap.

As shown, the flange 202 is provided with a series of markings "3M" spaced along the length of the cord 201 to identify the manufacturer of the product 200. It will be appreciated that the compressed region 202 may be provided with any other form of surface pattern as described above.

21-23, a fourth embodiment of a foamed product 300 according to the present invention is shown.

Foamed product 300 includes two elongated cords 301, 301 ′ of generally circular cross section joined together by a series of compressed regions or webs 302. The compressed region 302 is longitudinally spaced by the cutout region 303 during the molding process. As shown, each compressed region 302 is provided with a marking "3M" that identifies the manufacturer of the product 300. It will be appreciated that the compressed region 302 may be provided with any other form of surface marking as described above.

The product 300 may be produced by compressing a flat sheet of foam with a rotating blade (not shown) having a peripheral surface shaped to form a compressed region 302 and a cut out region 303.

The cords 301, 301 ′ can be used to help position the cords 301, 301 ′ when used as a masking material to mask gaps between two parts of a vehicle during spray coating, as described above. The tabs may be separated by cutting through the compressed region 302 to provide respective codes 301, 301 ′. In this application, the cords 301, 301 'are provided with longitudinal adhesive strips (not shown) to hold the cords 301, 301' in place.

It will also be appreciated that the present invention provides a surface pattern applied to a region of shaped material under pressure to retain the desired shape upon pressure relief in an article of compressible polymeric material. The surface pattern may be decorative and / or functional and may be formed concurrently with the molding process by appropriate configuration of the contact surface of the molding machine employed to compress the polymeric material.

Alternatively, the surface pattern may be applied to the area by a separating operation, for example by laser cutting or any technique before or after the forming operation. Separate molding operations may be used to apply surface patterns to one or both sides of the molded area. If the pattern is applied to one side, the other side may be flat. If the pattern is applied to both sides, the pattern may be the same or different and may be aligned or offset.

While the present invention has been described with particular reference to products made of polymeric foams suitable for use as masking materials in vehicle spray coating, the present invention is not limited to these uses, and the present invention is intended to retain the desired form upon pressure relief. It will be appreciated that it may be applied to other articles made of polymeric foams that can be molded under pressure.

For example, referring to Figures 24-26, an application of the present invention to a product 400 suitable for use in packaging eggs or similarly fragile items (not shown) is shown. As shown, each compacted region 401 is generally star shaped, aligned in two mutually perpendicular directions to create a convex surface that forms a recess or pocket 402 of the foam sheet containing the egg. The sheet of foam is compressed to provide a plurality of regions 401.

Region 401 is created by compressing the foam sheet with a molding machine (not shown) having a contact surface corresponding to the star shape of region 401. In this embodiment, the contact surface is formed with a recessed notch that provides a surface pattern in the form of parallel ribs 403 raised to the area. Region 401 may be provided with other surface patterns having decorative and / or functional natures as described herein. The product 400 may also be suitable for other uses, such as soundproofing or sound dampening materials for various applications.

Referring now to FIG. 27, an article comprising a foamed back pressure sensitive adhesive tape 501 provided with a flange 502 to which a surface pattern including the marking “3M” is applied along one side edge as previously described herein ( Application of the present invention to 500 is shown. The flange 502 is formed by compressing an area of the foam to retain the desired shape of the flange 502 upon pressure relief. It will be appreciated that any other surface pattern having decorative and / or functional properties as described herein may be applied to the flange 502. Flange 502 may be attached through a seam that allows flange 502 to be separated from tape 501 if desired.

In the embodiments described above, the region of the product is modified under pressure to retain the desired shape upon pressure relief applied to the region. Depending on the material of the article and the pressure applied, the deformation of the material may be sufficient for the material to retain the desired shape without additional energy input. For example, the applied pressure to deform the material may set the material to prevent the material from returning to its original form. In some cases, however, it may be desirable or necessary to provide additional input of energy to help retain the desired form of product upon pressure relief. This may be accomplished in various ways to reinforce or optimize the molding process. For example, it is achieved by applying a pressure higher than the pressure required for deformation to the material, or applying heat to the material, or by other means such as electromagnetic radiation or ultrasonic waves. The heat may be applied in any other suitable way, either by varying the ambient temperature or by heating the molding machine used to mold the material. One or more of these means for inputting additional energy may be employed separately or in combination.

The above-described embodiments have been described with the intention of illustrating the various scopes and uses of the invention, and the features of these embodiments relate to products having a surface pattern that is applied to the area of the product that is compressed to retain the desired shape upon pressure relief. It will be appreciated that it may be used separately or in combination with any other feature of the same or other embodiments to produce.

Thus, it will be appreciated that the present invention has general use as any article of compressible polymer material, in particular as a foam article in which decorative and / or functional surface patterns may be applied to the compressed region for any desired purpose. . For example, the present invention may be applied to headliners for cars, carpet underlays, and other products in which surface patterns can be usefully applied.

Moreover, it is believed that the specific materials and / or shapes of the products described and illustrated represent excellent means currently known for producing products having surface patterns that are applied to areas to retain the desired shape upon pressure relief, but the present invention Is not limited thereto, and it will be understood that various modifications and improvements can be made within the spirit and scope of the claims.

<Overview of invention>

According to a first aspect of the present invention, there is provided a polymer product provided with a pattern applied to an area of the product which is formed into a desired shape by deforming the area under pressure such that the desired shape is created in the deformed area upon pressure relief.

The molding process may be applied to open or closed cell polymer materials to compress and melt the cells together. The molding process may result in full or partial compression and melting of the cell. The molding process may result in permanent cell compression and fusion to retain and retain the desired shape of the product. Alternatively, the compression and melting of the cell may be semi-permanent such that the desired form of the product is retained and retained for a period of time after the product has returned to its original or substantially original form. For example, a semipermanent form may be used to indicate the service life of a product.

Depending on the material of the article and the pressure applied, the deformation of the material may be sufficient to make the material retain the desired shape during the molding process without additional energy input. In some cases, however, the molding process may be enhanced by providing additional energy input to help retain the desired form of the product upon pressure relief. This may be accomplished in various ways. For example, it may be achieved by increasing the pressure applied to deform the material, or by the application of heat to the material, or by other means such as electromagnetic radiation or ultrasound.

The surface pattern may be functional to give the product the desired properties, or decorative to reinforce the aesthetic properties of the product, or a combination of both.

In one embodiment, the surface pattern may alter the physical properties of the applied area. For example, the surface pattern may include features such as ribs arranged to alter the stiffness, strength or flexibility of the shaped region or to provide stress relief.

In other embodiments, the surface pattern may provide or include a visual display of information. For example, the information may be in the form of indicia such as letters, numbers, symbols or pictures applied to the molded area. Such information may provide the end user with information identifying the product and / or manufacturer to identify the authenticity. Alternatively or in addition, the information may provide a method of using the product.

Advantageously, the surface pattern is applied during the molding process. For example, molding machines such as forming dies and / or cutting blades may be provided with contact surfaces adapted to provide a desired surface pattern for the compressed polymeric material. By applying the surface pattern in this manner, the surface pattern cannot be easily removed, damaged or changed without these visually apparent changes. Alternatively, the surface pattern may be applied before or after the molding process, for example by laser cutting or other suitable forming / molding technique.

The surface pattern may be provided on one or both sides of the molded area. When the surface pattern is applied to one side during the molding process, the inverse of the surface pattern is formed on the opposite side. Thus, it is also possible to form areas of the product in the nip between a pair of rollers applied to one or both rollers, for example having a surface pattern etched on the surface of the roller.

The surface pattern may be applied to each side during the molding process, or the pattern may be offset so that the inverse pattern does not interfere with the pattern applied to the opposite side. Alternatively, the surface pattern may be applied to both sides such that the inverse pattern overlaps the pattern applied to the opposite side.

When the surface pattern is applied to both sides that are offset so as not to interfere with each other, the patterns may be the same or different, or may be offset in the longitudinal direction of the product. For example, a decorative pattern may be applied to one side and information may be applied to the other side.

When applying surface patterns to overlapping sides, the patterns may co-operate to produce a combined surface pattern on both sides that may provide decorative and / or informational.

If the surface pattern is applied separately from the molding process, for example laser cutting, the pattern may only be applied to one side. Alternatively, the pattern may be applied to both sides. The patterns thus formed may be the same or different and may be aligned or offset.

The surface pattern has the same surface finish as the adjacent polymer material, for example color, texture. Alternatively, the elevation pattern has a different surface finish. For example, the surface pattern may be a contrast color or a texture. In this way, the visibility of the surface pattern can be enhanced. This may be particularly useful when surface patterns are employed to provide information to the end user.

In one configuration, the portion of the contact surface forming the surface pattern may be provided with a coloring material transferred to the polymer material on which the surface pattern is formed. Alternatively or additionally, other surface finishes (textures) may be provided that are added to the polymeric material on which the surface pattern is formed.

Preferably, the article is made of a polymeric foam material, for example an open or closed cell polymeric foam, which is elastically compressible and can be formed into a desired form under pressure. Polymers having a density in the range of 20 to 30 Kg / m 3 are usually suitable, and include foam materials such as polyurethanes, polyolefins, polyesters and the like.

In one embodiment, the shaped area is of reduced thickness compared to adjacent areas of the article. If the product is in the form of an elongated strip for use as a masking material, the shaped region may extend along the length of the strip and may be continuous or discontinuous.

The molded area may provide the product with properties suitable for the intended use of the product. Thus, the shaped region may form a hinge extending along the length of the long strip to be used as the masking material so that the adjacent portions of the strip can be hinged with respect to the shaped region.

Alternatively or additionally, the molded area may provide a tab that the product can grab to assist in handling the product in use. If the article is in the form of a long strip for use as a masking material, the tabs may be continuous along the length of the strip, or a series of tabs may be provided spaced along the length of the strip.

The shaped region may comprise a seam formed by fully compressing and melting the cells together. The seams may be continuous or discontinuous along the length of the product. The seam provides a fragile line that may be linear, curved or other suitable shape such that the area adjacent to either side of the seam is separated along the seam. For example, two or more products may be formed together and detachably secured to each other by seams to allow the products to be separated from each other. Alternatively, if a tab is provided, it may be connected to the product by a seam so that the tab can be removed after the product is secured in place.

The polymeric material may be a natural or synthetic polymer. Synthetic polymers may include polyesters, polyurethanes and polyolefins. Natural polymers may also include polioses such as cellulose. Preferred polymeric materials are foams, but other materials can be used, including elastomers, thermoplastics and nonwoven materials that can be molded under pressure. The polymeric material may be a combination of two or more polymeric materials.

According to a second aspect of the present invention, there is provided a method of marking an article made of a polymeric material, comprising forming an area of the article by applying pressure to the polymeric material, and applying a surface pattern to the shaped region. .

Preferably, the surface pattern is formed during the molding process to compress the polymeric material. The surface pattern may be inserted below the proximal face of the shaped region. Alternatively, the surface pattern is raised above the adjacent surface of the shaped area. For example, a forming die forming the area to be shaped may be provided with a contact surface into which a surface pattern is raised or inserted below the contact surface.

According to a third aspect of the present invention, there is provided a method of making a product made of a polymeric material, comprising means for compressing a portion of a product to form a region of reduced thickness and means for applying a surface pattern to the region thus formed. An apparatus for is provided.

The compression means may comprise a molding machine such as a forming die or blade having a contact surface for forming a region of reduced thickness by compressing the polymeric material. The surface pattern applying means may comprise a portion of the contact surface provided with the surface pattern. In this way, the surface pattern is formed as an integral part of the compressed region.

According to a fourth aspect of the present invention, an elongated foam strip is provided for use as a masking material for masking a gap between two relatively movable parts, the foam strip having a foam strip on one of the parts to close the gap momentarily. And an adhesive strip for detachably fixing the adhesive, and a surface pattern provided in a region formed in a desired shape under pressure.

These and other features, advantages and advantages of the present invention will be more fully understood from the following description of exemplary embodiments of products according to the invention and methods and devices for making such products.

Claims (65)

A polymer product provided with a surface pattern applied to an area of the product, which is formed into a desired shape by deforming the area under pressure such that upon removal of pressure, the desired shape is created in the deformed area. The polymeric article of claim 1, wherein the surface pattern has functionality. The polymeric article of claim 2, wherein the surface pattern modifies the physical properties of the article. The polymeric article of claim 3, wherein the surface pattern modifies at least one of stress, stiffness, strength, or flexibility of the article. The polymeric article of claim 2, wherein the surface pattern provides or comprises a visual display of information. The polymeric article of claim 5, wherein the information comprises one or more indications. The polymeric article of claim 6, wherein the indication comprises one or more letters, numbers, symbols, or figures. The polymer product of claim 5, wherein the information identifies the product and / or the manufacturer. The polymeric product of claim 5, wherein the information provides a method of using the product. The polymeric article of claim 1, wherein the surface pattern is decorative. The polymeric article of claim 1, wherein the surface pattern is applied during the molding process. The polymeric article of claim 11 wherein the surface pattern is applied to a molding machine having a contact surface adapted to provide a desired surface pattern to the compressed polymeric material. 13. The polymeric article of claim 11 or 12, wherein a surface pattern is applied to one side of the compressed region and an inverse pattern is formed on the opposite side. The polymeric article of claim 11, wherein the surface pattern is applied to both sides of the compressed region. The polymeric article of claim 14 wherein the surface pattern on one side is offset relative to the surface pattern on the other side. The polymer article of claim 14, wherein the surface pattern on one side overlaps the surface pattern on the other side. The polymeric article of claim 14, wherein the surface pattern on each side is the same. The polymer article of claim 14, wherein the surface patterns on each side are different from each other. The polymeric article of claim 1, wherein the surface pattern is the same color as the adjacent polymeric material. The polymer article of claim 1, wherein the surface pattern is in a color that contrasts with adjacent polymer articles. The polymeric article of claim 1, wherein the surface pattern is raised relative to the adjacent polymeric material. The polymeric article of claim 1, wherein the surface pattern is recessed relative to the adjacent polymeric material. 23. The polymeric article of any one of claims 1 to 22 made of a polymeric foam material. The polymeric article of claim 23, wherein the polymeric foam is an elastically compressible open or closed cell polymeric foam and can deform under pressure to retain the desired shape upon pressure relief. The polymeric article of claim 23 or 24, wherein the polymeric foam has a density in the range of 20 to 30 Kg / m 3. The polymeric article of claim 23, wherein the polymeric foam is selected from the group comprising polyurethanes, polyolefins, and polyester foam materials. 23. The polymeric article of any one of claims 1 to 22 made of a polymeric material selected from the group comprising elastomers, thermoplastics and nonwoven materials. 28. The polymeric article of any one of the preceding claims in the form of an elongate strip. The polymeric article of claim 28, wherein the compressed region extends along the length of the strip. The polymeric article of claim 29, wherein the compressed region is continuous in the longitudinal direction of the strip. 30. The polymeric article of claim 29 wherein the compressed region is discontinuous in the longitudinal direction of the strip. 32. The polymeric article of claim 29, wherein the compressed region has a width transverse to the length of the strip. 33. The polymer article of any one of the preceding claims, wherein the compressed region provides a product having properties suitable for the intended use of the product. 34. The polymeric article of claim 33 wherein the compressed region forms a hinge extending along the length of the long strip to be used as the masking material such that the proximal portion of the strip can be hinged relative to the compressed region. 34. The polymeric article of claim 33, wherein the compressed region provides a tab that the article can grip to assist in handling the article in use. The polymeric article of claim 35, wherein the article is in the form of an elongated strip and the tabs are continuous in the longitudinal direction of the strip. 36. The polymeric article of claim 35, wherein the article is in the form of an elongated strip and the series of tabs are provided spaced apart in the longitudinal direction of the strip. 38. The polymeric article of any one of claims 1-37, wherein the compressed region comprises a seam. The polymeric article of claim 38, wherein the article is in the form of an elongated strip and the seam is continuous along the length of the article. The polymeric article of claim 38, wherein the article is in the form of an elongated strip and the seam is discontinuous along the length of the article. 41. The polymeric article of any of claims 38-40, wherein the adjacent region is separable along the seam. 42. The polymeric article of any of claims 38-41, wherein the two or more articles are molded together and detachably secured to each other by seams to allow the articles to separate from each other. The polymeric article of claim 38, wherein the tab is provided connected to the article by a seam to allow the tab to be removed after the article is secured in place. The polymer article of claim 1 comprising an elongated foam strip for use as a masking material. Applying pressure to the polymeric material to shape an area of the article, and A method of marking an article of polymeric material comprising providing a surface pattern in a molded area. 46. The method of claim 45, wherein the surface pattern is formed during the molding process to compress the polymeric material. 47. The method of claim 45 or 46, wherein the surface pattern is inserted below an adjacent surface of the compressed area. 47. The method of claim 45 or 46, wherein the surface pattern is raised above the adjacent surface of the compressed area. 49. The method of any one of claims 45-48, wherein the surface pattern is produced by a forming die that forms a compressed region. 50. The method of claim 49, wherein the die is provided with a contact surface with a surface pattern raised above the contact surface. The method of claim 49, wherein the die is provided with a contact surface with a surface pattern inserted below the contact surface. 52. The method of any one of claims 45-51, wherein the surface pattern is applied to one side of the compressed region and forms an inverse pattern on the opposite side. 52. The method of any one of claims 45-51, wherein the surface pattern is offset with respect to the surface pattern applied to opposite sides of the compressed region. 52. The method of any one of claims 45-51, wherein the surface pattern overlaps a surface pattern applied to opposite sides of the compressed region. 55. The method of claim 53 or 54 wherein the surface patterns applied to both sides are the same. 55. The method of claim 53 or 54, wherein the surface patterns applied to both sides are different from each other. 57. The method of any one of claims 45-56, wherein the shaping process is assisted by additional input of energy. 59. The method of claim 57, wherein an additional input of energy is provided by applying a high pressure. 59. The method of claim 57 or 58, wherein an additional input of energy is provided by applying heat. 60. The method of any one of claims 57-59, wherein additional input of energy is provided by electromagnetic radiation. 61. The method of any one of claims 57-60, wherein additional input of energy is provided by ultrasound. Means for compressing a portion of the article to form an area of reduced thickness, and A device for making a product of polymeric material, comprising means for providing a surface pattern to a region. 63. The apparatus of claim 62, wherein the compression means comprises a molding machine having a contact surface for forming regions of reduced thickness by compressing the polymeric material. 63. The apparatus of claim 62 wherein the surface pattern applying means comprises a portion of the contact surface provided with the surface pattern. An adhesive strip for detachably securing the foam strip to one of the parts to close the gap instantaneously, and An elongated foam strip for use as a masking material for masking gaps between two relatively movable parts, having a surface pattern provided in a region that is formed in a desired shape under pressure.